jhughes2013

I had this happen to me. It was a snapped axle shaft. The loud hammer noise I had came from the way the axle fractured. It fractured diagonally and every rotation would push the end of the shaft outwards and it would pop back in from the pressure of the CV shaft. Took me a while to figure it out because I was not four wheeling hard at all and the axle shouldn't have broke. I ended up jacking up each side and spinning the driveshaft and that is when I noticed the axle getting push out of the housing. "Not cool" I thought, but it only ended up being about $150 for the axle shaft. I repaired it in my brother's tool-less garage (on vacation) with my box of hand tools and 2 jacks. Most of the time was spent cleaning the metal pieces out of the diff. Good luck. If you lived near Central FL I would give you a hand. I'm also a master at changing those pesky window regulators. Only takes about 10 min. The only one I haven't replaced is the front passenger side.

Oh yea...I wouldn't take the IWE apart unless you have narrowed the problem down to there. The hubs and actuator were the first things I looked at and it ended up being a much more obvious problem.

FX-4inparadise

No offense taken, and no the wheels where not spinning when using the "Shift On The Fly" I have used it while driving under the 50 mph limit

FX-4inparadise

J, thanks for all that great info! Thanks for that offer to help too! Y would these things break under such light use. My Problems started with some short runs through the sand.......go figure "BUILT FORD TOUGH"